08 Mar 2007
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Robotics Application
Design and Manufacturing Services
Requirement
Micromech, specialists in robotics and control systems, were working with a major UK manufacturer of bathroom furniture to automate one of their key ceramic manufacturing processes. Automating the process was designed to increase efficiency, increase product throughput, and reduce the manufacturing costs.
Solution
Product Assurance Group were tasked by Micromech to design and realise the mechanical components. It was the first known use of the automated drilling of ceramics. The major part of Product Assurance Group’s work was developing the various tools required. These were mounted on the end of a robot arm, and performed all of the tasks previously carried out manually. Four different tools were developed, each of which performed specific tasks within the manufacturing process. These tools embodied a range of electro-mechanical functions; including drive systems, load cells, pneumatic pistons, optical sensors, and complex mechanical linkages. Computer Aided Design (CAD) tools were utilised to help design the overall system. This allowed all the parts to be modeled in place and any clashes eliminated. An important part of the design phase was to ensure that the new hardware was structurally sound, and capable of withstanding the loadings to which it would be subjected. To this extent, both manual calculations and Finite Element Analysis were used. Product Assurance Group were also responsible for the manufacture and site installation of its parts of the design.
Benefits
The new robotic cells produced by Product Assurance Group and Micromech, of which there are now two, can automatically manufacture sixteen units in approximately twenty minutes, completely finished and ready to be glazed and fired. This is a huge improvement on the previous manual method.
